Cam Chain Tensioner Tool broke and stuck in Tensioner!!!

[ShawnSV]

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[nynoah]

You are going to have to pull the cams off. Make sure you set the timing marks between the crank and the heads. Then take it all apart. You might be able to get away with just pulling the intake cam alone. Then take out the Cam Chain tensioner and deal with it. I would also count the chain links between the cams. Because it is very likely the chain will fall off the cams when you pull the one cam. This is fixable. Just take a breath and and remember that a human put it together and you can service it too.

I am also surprised it broke that way. Did you cross thread? The usual area it breaks is in the top section ears from being over tightened.

[nynoah]

Here this might help

http://forums.quattroworld.com/a8/msgs/55496.phtml

[bhusted]

Here this might help

http://forums.quattroworld.com/a8/msgs/55496.phtml

^This is what I would recommend. Drilling inside the head is going to put metal shavings into the oil. Put the engine at TDC if you haven't already. You really should do this as a first step any time you're messing with timing components.

Use some brake cleaner on a rag to clean the oil of of the cam sprockets and chain. Use a paint marker to mark where one roller meets each sprocket. This makes reinstalling the intake cam much easier. Stuff a rag/shop towel between the head casting and the chain on the exhaust sprocket. This will prevent the chain from slipping on the exhaust cam. Pull the cam caps on the intake cam and the one exhaust cam cap next to the chain. You can now lift out the intake cam and tensioner as one piece.

While you're in there you'll want to replace the gasket, half moon seal, and probably the seal on the front end of the intake cam.

[walky_talky20]

^This. All of this. Pulling the intake cam is all you should need to do. The exhaust cam (and timing belt and all that entails) can stay put.

Don't worry, Shawn. You got this.

Nice photos, by the way.

[zillarob]

Man, that is a rough one

Ive never seen one break like that, and think it is usually the plastic part that snaps off if you get ramy with it.
I would fear being crossthreaded and seized up is what might have caused it to break like that.
If were my car, and I thought this were the case, I might be inclined to try leaving it. If its fkd up, whats the point of taking it out?

[Quattro420]

You might be able to spin it with a long pick or a left handed drill bit as long as it's not cross treaded then the bolt won't be tight i try it befor I touched the intake cam

[bhusted]

You can get the tensioner pads on ebay for pretty cheap. I've got some spares that I'd be willing to part with for the cost of shipping as well. LMK.

[andyrew]

You can get the pads on Amazon as well if you prefer that method.

[redline380]

If you were done with the procedure, I would have just left it.

But so goes it. I was working at a shop the last couple weeks and they had a big logging skidder type thing with 8x8 wheel drive. Two of the rear wheels which are tied together with gears were locked up. I took off the bearing cover to access the shaft that drives that set of wheels. The shaft came out, but only half of it, with the half stuck in there having a smaller diameter than the half we pulled out. And because the brake discs ride on that shaft, the shop owner didnt want to realse the brake and lose the splined discs. So what we did was put a pvc pip in the hole, which was small enough on the outside to fit, but big enough on the inside so the shaft could come out.

I tried getting the shaft out with a magnet, but no go. It was slightly stuck. So the owner fired up the old stick welder and put two stick welded together in the tube. He struck an arc and got the stick melted to the shaft. After I shut the welder off, he pulled the shaft out through the pvc pipe. I thought it was cool as hell. Turns out the planetary gears exploded so everything had to come apart anyways.

Not sure why I just typed out that story but I went to far to delete it. Your situation just made me think of it.